U.S. patent number 4,191,443 [Application Number 05/820,038] was granted by the patent office on 1980-03-04 for electrical connector means.
This patent grant is currently assigned to Slater Electric Inc.. Invention is credited to Richard C. Doyle.
United States Patent |
4,191,443 |
Doyle |
March 4, 1980 |
Electrical connector means
Abstract
An electrical connector assembly for coupling the end of one
electrically conductive cable to another includes a connector front
formed with a pair of oppositely disposed legs extending rearwardly
from its front face, a terminal housing releasably lockably
engageable by projections on the legs to form a connector body with
electrical contacts therebetween and a connector housing releasably
lockably engageable by a latching sear on the end of each leg for
coupling the connector body to the connector housing. In addition,
a collar member is threaded onto the other end of the connector
housing with a chuck member positioned therebetween for
tighteningly grasping the cable. Advantageously, the chuck member
includes extensions adapted to be positioned behind each sear for
preventing inadvertent disassembly of the connector body from the
connector housing. Also advantageously, the terminal housing is
formed with a slot extending radially outwardly from the center
thereof, with one projecting surface adapted to abut the radially
inward surface of the head of an elongate ground terminal screw and
another projecting surface adapted to abut the radially outward
surface of a flange formed on the grounding screw for retaining the
ground screw which is threaded into a contact plate for moving
toward another contact plate adapted to bear against a flange on
the screw to enable termination of the ground conductor by
inserting it into the spacing between contact plates and tightening
the plates together by threading the grounding screw.
Inventors: |
Doyle; Richard C. (Greenlawn,
NY) |
Assignee: |
Slater Electric Inc. (Glen
Cove, NY)
|
Family
ID: |
25229718 |
Appl.
No.: |
05/820,038 |
Filed: |
July 28, 1977 |
Current U.S.
Class: |
439/462;
439/598 |
Current CPC
Class: |
H01R
13/506 (20130101); H01R 13/516 (20130101); H01R
13/59 (20130101); H01R 13/652 (20130101); H01R
24/22 (20130101); H01R 24/30 (20130101); H01R
2103/00 (20130101) |
Current International
Class: |
H01R
13/506 (20060101); H01R 13/502 (20060101); H01R
13/516 (20060101); H01R 13/59 (20060101); H01R
13/58 (20060101); H01R 013/58 () |
Field of
Search: |
;339/101,103,196,209,14 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: McGlynn; Joseph H.
Attorney, Agent or Firm: Morgan, Finnegan, Pine, Foley &
Lee
Claims
What is claimed is:
1. Connector means adapted to be coupled to the electrical
conductors in an insulated electrical cable, comprising:
a terminal housing adapted to support electrical contact means and
to electrically isolate terminal portions of said electrical
contact means yet enable access thereto for coupling the conductors
to said terminal portions of said electrical contact means;
a connector front member adapted to be releasably lockably attached
on one side to one side of said terminal housing member, said
connector front member being adapted to permit access to contact
portions of said electrical contact means on its other side, said
terminal housing and said connector front member forming a
connector body when coupled together;
at least two generally flexible and resilient leg members formed on
said connector front member, extending in a direction
longitudinally back from its said other side, each said leg member
formed with first engaging means adapted to releasably lockably
couple said connector front member and said terminal housing
together to form said connector body, and each said leg member also
being formed with second engaging means;
a generally cylindrical connector housing member, said connector
housing member adapted to receive said connector body and the cable
when coupled to said terminal housing, said connector housing
adapted to be releasably lockably attached to said connector body
by said second engaging means; and
means associated with said connector housing for tighteningly
grasping the cable when the conductors are coupled to said terminal
portions to retain the cable fixed relative to said connector
housing; such that said terminal housing, said connector front
member and said connector housing can be retained in assembled
configuration by said first and second engaging means without
threaded fasteners.
2. Connector means according to claim 1 wherein said leg members
and said first and second engaging means are formed integrally with
said connector front member.
3. Connector means according to claim 2 wherein said terminal
housing is formed with first abutment means adapted to be engaged
by said first engaging means and wherein said first engaging means
comprise first latching means adapted to abut said first abutment
means when said terminal housing is releasably lockably coupled to
said connector front member, such that when said first latching
means are located in abutting relation with said first abutment
means, disengagement of said terminal housing from said connector
front is substantially prevented.
4. Connector means according to claim 3 wherein said connector
housing is formed with second abutment means adapted to be engaged
by said second coupling means and wherein said second engaging
means comprise second latching means adapted to abut said second
abutment means when said connector body is lockably coupled to said
connector housing, such that when said second latching means are
located in abutting relation with said second abutment means,
disengagement of said connector housing from said connector body is
substantially prevented.
5. Connector means according to claim 3 wherein said first latching
means comprise a pair of projections extending outwardly from the
longitudinally extending side edges of said leg member, and wherein
said terminal housing is formed with a pair of slots positioned
therein to slidably receive said leg members during assembly of
said connector body, each said slot formed with a pair of radially
outwardly sloping ledge portions on its longitudinally extending
side walls, each said sloped ledge portion terminating to form an
abutment surface extending generally perpendicular to said slot at
the back end of each ledge, such that as said terminal housing and
said connector front member are being coupled together, said leg
members are generally slidably received in said slots and said
projections ride along said ledge portions to force said legs
members radially outwardly apart until said projections resiliently
snap radially inwardly generally in a ratchet-like manner, behind
said abutment surfaces, whereby said projections bear against said
abutment surfaces to prevent separation of said terminal housing
and said connector front member.
6. Connector means according to claim 5 wherein said ledges slope
radially outwardly towards the outer surface of said terminal
housing before terminating at said first abutment means.
7. Connector means according to claim 5 wherein the free end of
each leg member is formed with sear means extending radially
outwardly therefrom and wherein said connector housing is formed
with lip means positioned to correspond to each said sear means
such that as said connector body and said connector housing are
being coupled together, said sear means and said lip means are
coupled in a generally ratchet-like manner, whereby said engaged
sear and lip means prevent separation of said connector body and
said connector housing.
8. Connector means according to claim 7 wherein said lip means are
provided by apertures formed in said connector housing, said
apertures adapted to expose a portion of said sear means when said
connector body and said connector housing are coupled together such
that when separation of said connector body and said connector
housing is desired, said sear means can be pushed radially inwardly
past said lip means to disengage said sear means from said lip
means and permit separation of said connector body and said
connector housing.
9. Connector means according to claim 8 wherein said cable-securing
means comprise a collar member adapted for threadable engagement
with said connector housing and chuck means, said chuck means being
positioned between said collar and said housing and being adapted
to tighteningly grasp the cable as said collar means are threaded
onto said connector housing, said chuck means including a number of
extension members at least equal to that of said leg members, said
extension members adapted to project at least partially behind the
free ends of said leg members on the radially inward side thereof
when said chuck means have tighteningly grasped the cable, such
that radially inward depression of said sear means is substantially
resisted by said extension members to substantially prevent
inadvertent disassembly of said connector body and said connector
housing.
10. Connector means according to claim 9 which further includes a
generally wedge-shaped protuberance formed on the radially inward
surface of the free end of each said leg member to abut said
extension members when positioned therebehind.
11. Connector means according to claim 10 wherein said connector
front, said leg member, said projections, said sear means and said
protuberances are integrally formed from a moldable plastic
material.
12. Connector means according to claim 1 which further includes a
relatively elongate terminal screw, said screw having a threaded
portion generally at one end and a head at its other end and having
a flange between its two ends; wherein said terminal housing is
formed with a chamber interior thereof, adapted to support and
electrically isolate the terminal portion of an additional
electrical contact means, said additional contact terminal portion
including a fixed terminal plate affixed to the contact portion of
said additional contact means and a movable terminal plate, and
wherein said terminal housing is also formed with a slot extending
generally radially outwardly to the exterior surface of said
terminal housing to provide access to said chamber, said slot
having a first surface generally near the radially outermost end of
said slot, said first surface adapted to abut the radially inward
surface of said screw head, and a second surface radially inward of
said first surface, said second surface adapted to abut the
radially outward surface of said screw flange, such that the
threaded end of said screw can be freely inserted through an
unthreaded borehole formed in the said terminal plate and threaded
into a threaded borehole formed in said movable terminal plate for
bringing the terminal plates together to enabling wire clamp
termination of a conductor in the cable to said additional
electrical contact means.
13. Connector means according to claim 12 wherein said additional
electrical contact means is the ground contact of said connector
means and is located generally at the center of the front face of
said connector front and wherein the conductor wired thereto is the
ground conductor, such that the ground conductor can be simply
wired to the ground contact.
14. An electrical connector assembly for coupling the conductors of
two insulated electrical cables, comprising:
a first terminal housing adapted to support male electrical contact
means and to electrically isolate terminal portions of said male
electrical contact means yet enable access to said male terminal
portions for coupling to the conductors of one cable;
a first connector front member adapted to be releasably lockably
coupled on one side to one side of said first terminal housing
member, said first terminal housing and said first connector front
member forming a male connector body when coupled together, said
first connector front member adapted to expose blade portions of
said male electrical contact means on its other side, and said
first connector front member formed with at least two generally
flexible and resilient leg members extending longitudinally back
from its said other side, each said leg member being formed with
first engaging means adapted to releasably lockably couple said
first connector front member to said male terminal housing together
to form said male connector body, and each said leg member also
being formed with second engaging means;
a second terminal housing adapted to support female electrical
contact means and to electrically isolate terminal portions of said
female electrical contact means yet enable access to said female
terminal portion for coupling to the conductors of the other
cable;
a second connector front member adapted to be releasably lockably
attached on one side to one side of said second terminal housing,
said second terminal housing and said second connector front member
forming a female connector body when coupled together, the other
side of said second connector front being adapted to permit
engagement between receptacle portions of said female contact means
and said male contact blades, and said second connector front
member formed with at least two generally flexible and resilient
leg members extending longitudinally back from its said other side,
each said leg member being formed with first engaging means adapted
to releasably lockably couple said second connector front member
and said second terminal housing together to form said female
connector body, and each said leg member also being formed with
second engaging means;
two generally cylindrical connector housing members, each adapted
for receiving the end of one cable and one of said male and female
connector bodies, each said connector housing adapted to be
releasably lockably engaged by said second engaging means formed on
the leg members of the connector body releasably attached thereto
for releasably lockably securing the connector body to one said
connector housing; and
means associated with each said connector housing for tighteningly
grasping a cable when coupled to said one connector body to retain
the cable fixed relative to the connector housing, such that said
first terminal housing, said first connector front member and one
said connector housing can be assembled into a male connector
member with its said grasping means associated therewith without
threaded fasteners, and said second terminal housing, said second
connector front member and the other said connector housing can be
assembled into a female connector member with its said grasping
means associated therewith without threaded fasteners.
15. An electrical conductor assembly according to claim 14 wherein
said leg members and said first and second engaging means are
formed integrally with their said connector front members.
16. An electrical connector assembly according to claim 15, wherein
each said terminal housing is formed with first abutment means
adapted to be engaged by said first engaging means and wherein said
first engaging means on each said leg member comprise first
latching means adapted to abut said first abutment means when said
terminal housing is releasably lockably coupled to its
corresponding connector front members, such that when said first
latching means are located in abutting relation with said first
abutment means, disengagement of the terminal housing from its
corresponding connector front member is substantially
prevented.
17. A connector assembly according to claim 16 wherein each said
connector housing is formed with second abutment means adapted to
be engaged by said second engaging means and wherein said second
engaging means on each said connector housing comprise second
latching means adapted to abut said second abutment means when each
said connector body is lockably coupled to its corresponding
connector housing, such that when said second latching means are
located in abutting relation with said second abutment means,
disengagement of said connector housing from its corresponding
connector body is substantially prevented.
18. A connector assembly according to claim 16 wherein said first
latching means comprise a pair of projections extending outwardly
from the longitudinally extending side walls of each said leg
member, and wherein each said terminal housing is formed with a
pair of slots positioned therein to slidably receive said leg
members during assembly of said connector body, each said slot
formed with a pair of radially outwardly sloping ledge portions on
its longitudinally extending side walls, each said sloped ledge
portion terminating to form an abutment surface extending generally
perpendicular to said slot at the back end of each ledge, such that
as each said terminal housing and its corresponding connector front
member are being attached, said leg members are generally slidably
received in said slots and said projections ride along said ledge
portions to force said leg members radially outwardly apart until
said projections resiliently snap radially inwardly generally in a
ratchetlike manner, behind said abutment surfaces, whereby said
projections bear against said abutment surfaces to prevent
separation of said terminal housing and said connector front
member.
19. A connector assembly according to claim 18 wherein said ledges
slope radially outwardly towards the outer surface of each said
terminal housing before terminating at said first abutment
means.
20. A connector assembly according to claim 18 wherein the free end
of each leg member is formed with sear means extending radially
outwardly therefrom and wherein each said connector housing is
formed with lip means positioned to correspond to each said sear
means such that as each said connector body and its corresponding
connector housing are being coupled together, said sear means and
said lip means are coupled in a generally ratchet-like manner,
whereby said engaged sear and lip means prevent separation of each
said connector body and its corresponding connector housing.
21. A connector assembly according to claim 20 wherein said lip
means are provided by apertures formed in each said connector
housing, said apertures being adapted to expose a portion of said
sear means when each said connector body and its corresponding
connector housing are coupled together such that when separation of
the connector body from its corresponding connector housing is
desired, said sear means can be pushed radially inwardly past said
lip means to disengage said sear means from said lip means and
permit separation of each said connector body and its corresponding
connector housing.
22. A connector assembly according to claim 21 wherein said
cable-securing means for each connector member comprise a collar
member adapted for threadable engagement with each said connector
housing and chuck means, said chuck means being positioned between
said collar and said housing and being adapted to tighteningly
grasp a cable as said collar means are threaded onto said connector
housing, said chuck means including a number of extension members
at least equal to that of said leg members, said extension members
adapted to project at least partially behind the free ends of said
leg members on the radially inward side thereof when said chuck
means have tighteningly grasped the cable, such that radially
inward depression of said sear means is substantially resisted by
said extension members to substantially prevent inadvertent
disassembly of each said connector body and its corresponding
connector housing.
23. A connector assembly according to claim 22 which further
includes a generally wedge-shaped protuberance formed on the
radially inward surface of the free end of each said leg member to
abut said extension members when positioned therebehind.
24. A connector assembly according to claim 23 wherein each said
connector front, its said leg members, its said projections, its
said sear means and its said protuberances are integrally formed
from a moldable plastic material.
Description
BACKGROUND AND OBJECTS OF THE INVENTION
The present invention relates generally to connector means and,
more particularly, to electrical connector means known commercially
as "electrical caps and connectors". In addition, it will be
understood the description of the invention, contained herein, will
be equally applicable to plug connector means (the cable "cap") as
well as to receptacle connector means (the cable "connector").
The art is replete with connector devices for coupling the ends of
a pair of electrical cables. In virtually all of these devices
component parts have been secured together in assembled unit(s) by
metallic threaded fasteners - e.g. for fastening the terminal
housing to the connector front to form the connector body and/or
for fastening the connector body to the connector housing (outer
casing). Such structures, however, suffer several disadvantages.
Numerous small fastening screws are needed to complete
installation, requiring small tools, inconveniencing the
electrician and adding to fabrication costs. Furthermore, the
metallic fasteners are often installed on the surfaces of connector
bodies which are to face each other when plugged together. The
proximity of these metallic parts always gives rise to the
potential danger of a short circuit.
In addition, cap and connector apparatus heretofore known have
generally necessitated fabrication in more than one size in order
that most multi-conductor cables, particularly for four-and
five-conductor cables may be fitted with these devices. Thus,
significant additional fabrication expenses and efforts are
required.
Furthermore, in connector devices having a ground terminal/contact
located centrally of the connector front, it has been the practice
to wire the ground conductor of the cable to the ground terminal by
wrapping the conductor around a centrally located screw (i.e., by
binding screw termination) which is threaded into the ground
terminal. Usually, the ground conductor insulation must be removed
differently than the other conductors, inconveniencing the
electrician, and the convenience of wire clamp termination cannot
be utilized for wiring such ground terminals.
Accordingly, there is a need for a new and improved electrical cap
and connector assembly capable of relatively simple and inexpensive
fabrication; enabling speedy, secure and simple installation; and
characterized by safe and durable construction.
It is therefore an object of the present invention to provide new
and improved electrical connector apparatus. Another object of the
invention is to provide a new and improved electrical connector
apparatus capable of substantially speedy and simple
installation.
It is also an object of the invention to provide a new and improved
electrical connector apparatus characterized by dead front surfaces
having no exposed metallic parts with the exception of the
protruding plug prongs.
It is an additional object of the invention to provide a new and
improved electrical connector apparatus which can be assembled by
simply snapping together all major component parts.
It is yet another object of the invention to provide a new and
improved electrical connector apparatus which eliminates the need
for threaded fasteners for assembling the apparatus.
It is a further object of the present invention to provide a new
and improved electrical connector apparatus having component parts,
most of which can be fabricated from a moldable plastic
material.
It is still another object of the invention to provide new and
improved connector apparatus which can be simply adapted for a wide
range of multi-conductor cables and a wide range of amperage
ratings.
It is also another object of the present invention to provide a new
and improved electrical connector means which enables fast and
simple wiring of the ground conductor in connectors having a
centrally located ground terminal.
Objects and advantages of the invention are set forth in part
herein and in part will be apparent herefrom, or may be learned by
practice with the invention, the same being realized and attained
by means of the structures, instrumentalities and combinations
pointed out in the appended claims. Accordingly, the invention
resides in the novel parts, structures, arrangements, combinations
and improvements herein shown and described.
SUMMARY OF THE INVENTION
Briefly described, the improved connector apparatus according to
the present invention includes a connector front adapted to provide
access to electrical coupling means (i.e., a plug or a receptacle)
and formed with a pair of generally oppositely disposed leg
members, a terminal housing adapted to be releasably lockably
fastened to the connector front for retaining the terminal portions
of the electrical coupling means therebetween and providing access
to the terminal portions for connection to the cable conductors, a
generally hollow connector housing adapted to be attached to the
connector body (made up of the assembled connector front and
terminal housing) and means threadably engageable onto the
connector housing for tighteningly engaging the cable to hold it in
a fixed position in the housing and, thereby, relative to the
connector body. Advantageously, and as here preferably embodied,
the leg members are formed integrally with the connector front and
include first engaging means for releasably lockably coupling the
terminal housing to the connector front and second engaging means
for releasably lockably coupling the assembled connector body to
the connector housing.
As preferably embodied, the second engaging means comprises a sear
member formed at the end of the leg member and the housing is
formed with an aperture adapted to receive the sear in a
ratchet-like manner and provide a lip for engagement by the sear
for lockably coupling the connector body and the housing. Also as
preferably embodied, the means for tighteningly engaging the cable
includes a collar threadably engageable onto the housing with a
chuck member positioned therebetween for tighteningly grasping the
cable, and the chuck member is formed with extensions adapted to be
positioned radially inwardly of and behind at least a portion of
the sear formed on the leg, when the chuck is tightened onto the
cable.
According to another aspect of the present invention, the connector
body may be formed with a radially extending opening having a pair
of surfaces extending into the opening, generally perpendicular to
the radial direction, with one radially inward of the other. The
opening is adapted to receive a screw which is at least as long as
the connector body radius with the outer surface adapted to abut
the radially inward surface of the head of the screw and the inner
surface abutting the radially outward surface of a flange formed on
the screw so that the screw is restrained from movement in radial
direction and the end of the screw extends through the terminal
plate of the ground terminal/contact and is threaded into a movable
terminal plate so that threading the screw into the movable plate
enables the plates to be tightened against each other.
It will be apparent from the foregoing general description that the
objects of the invention as here embodied. Thus, it has been found
that connector means made in accordance with the present invention
are capable of quicker and easier assembly than caps and connectors
heretofore known.
In addition, by constructing electrical caps and connectors in
accordance with the present invention, it has been found that the
component parts may be made in essentially one size, yet
accommodate substantially all multi-conductor cables, for a wide
range of amperage rating.
It has also been found that by providing a connector front formed
with leg members having first and second engaging means, the
electrical connector assembly can be assembled together without any
metallic threaded fasteners except for those which may be used for
wiring the cable conductors to the electrical terminals in the
connector body.
In addition, by providing the opening in the connector body with
the pair of surfaces as well as an elongate ground screw having a
flange thereon, the ground conductor in the cable can be
conveniently wired and prepared for wiring in essentially the same
manner as the other conductors in the cable.
Furthermore, by constructing cap and connector apparatus according
to the invention, the component parts may, with the exception of
the electrical conducting and connecting elements, be made from a
moldable plastic material.
It will be understood that the foregoing general description, as
well as the following detailed description are exemplary and
explanatory of the invention but are not intended to be restrictive
thereof. Thus, the accompanying drawings, referred to herein and
constituting a part hereof, illustrate preferred embodiments of the
invention and, together with the detailed description, serve to
explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view of a preferred embodiment
according to the present invention.
FIG. 2 is a section view of the embodiment in FIG. 1 in assembled
and coupled configuration.
FIGS. 3a-c are various sectional views showing the operative
positions of preferred chuck means according to the invention.
FIG. 3d is a view along Section 3d-3d of FIG. 3c.
FIGS. 4a and b are section and plan views, respectively of a
preferred connector housing according to the invention.
FIG. 5 is an enlarged plan view of a portion of a partially
assembled connector assembly according to the invention, showing a
leg member lockably engaged with the terminal housing by first
engaging means formed on the leg.
FIG. 6 is a view taken along lines 6--6 of FIG. 5.
FIG. 7 is an enlarged view similar to FIG. 5 of the terminal
housing, a leg member and the connector housing coupled together in
accordance with the invention.
FIG. 8 is a view taken along section lines 8--8 of FIG. 7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring generally to the accompanying drawings, wherein like
reference characters refer to like parts throughout the various
views, there is shown a preferred embodiment illustrating the
various aspects of the present invention. It will be understood
that throughout the various figures described hereinafter, the same
reference numbers will be used to identify th same or analogous
component elements of both the male and female connector elements,
since, except for the connector fronts, the present invention
enables the use of identical component parts for both connector
sections. Thus, the following description is intended to apply to
both the male and female connector sections.
Referring now, more particularly to FIGS. 1 and 2 there are shown
section views of the connector assembly in exploded and
assembled/installed configurations, respectively. According to the
embodiment illustrated in FIGS. 1 and 2, each connector member
(i.e., the male member and the female member) is formed with
connector body 106 (made up of connector front 100 and terminal
housing 104), connector housing 110 and means for tighteningly
engaging the electrical cable (indicated at 130), here in the form
of collar 116 and chuck means 120. As preferably embodied,
connector front 100 is formed with a pair of leg members 102 which
are preferably formed integral with connector front 100 and extend
rearwardly of its front face (i.e., the face adapted to abut the
other electrical connector section) and parallel to the
longitudinal axis of the assembled connector member.
According to one aspect of the invention, each leg 102 is formed
with means for releasably lockable engaging terminal housing 104 to
retain connector front 100 and terminal housing 104 assembled
together and form connector body 106, with the terminal portions of
either the male electrical plug elements or female electrical
receptacle elements contained in terminal housing 104 and the
electrical plug or receptacle portions suitably exposed by
connector front 100 for coupling together (i.e. with the plug
portions extending from the front surface of the male connector
front and the receptacle portions housed in the female connector
front which is formed with suitable slots adapted to permit access
to the receptacle portions by the plug prongs). To this end, each
leg 102 is formed with projections 103 extending perpendicularly
outwardly therefrom in the circumferential direction of the
assembled connector member from the edges of each leg 102 which
have a dimension in the radial direction (indicated at 102a). In
addition, terminal housing 104 is formed with a pair of slots 105,
positioned for corresponding to and slidably receiving legs 102 for
releasably locking legs 102 therein.
As previously embodied, each slot 105 is formed with a pair of
ledges 105a, one on each of its side walls, for guiding projections
103 as legs 102 are slid into slots 105. Advantageously, ledges
105a are sloped in the radial direction, increasing in inclination,
radially outwardly, in the direction of insertion of legs 102 into
slots 105, and terminate to form an abutment surface behind the
point of greatest slope. Also as preferably embodied, the end
portion of sloped ledges 105a (i.e., the portion closest to the
termination point) have a slightly greater slope than the front
portion of ledges 105a to facilitate the ratchet-like action
described below. Moreover, ledges 105a preferably terminate at the
outer surface of the terminal housings and form a small part of the
outer surface (as evident from FIG. 1), to provide a broad abutment
surface 105b, extending in the radial direction, for engagement by
projections 103.
Thus, as connector front 100 and terminal housing 104 are brought
together for assembly to form connector body 106, legs 102 are
inserted into slots 105 and projections 103 ride along ledges 105a
and cause legs 102 to be increasingly spread apart until the point
of maximum slope of ledges 105a, whereafter projections 103 snap
radially inwardly, in a generally ratchet-like manner, to bear
against abutment surfaces 105b (See FIGS. 5 and 6). In this way,
separation of connector front 100 and terminal housing 104 is
prevented by projections 103 bearing against abutment surfaces
105b. Moreover, assembly of conductor body 106 may thereby be
accomplished in a simple single-step operation, without the need
for screws or other metallic and/or threaded fasteners.
Also according to the invention, each leg 102 is additionally
formed with means for releasably lockably engaging connector
housing 110. To this end, the free end of each leg 102 is formed
with sear means 108 adapted to releasably lockably engage lip
means, preferably provided at edge 113 of aperture 112, which are
formed in connector housing 110. Advantageously, lip means 113
include projection 113a (see, e.g., FIG. 2) extending radially
inwardly from the interior surface of housing 110 to provide
additional structural strength behind lip 113 for withstanding the
bearing force transmitted by the engaging surface (indicated at
108a) of sear means 108 when any attempt is made to pull apart the
assembled connector body and connector housing. In addition, both
the leading edge of sear 108 and the back edge of projection 113a
are formed with reciprocally sloping surfaces to facilitate passage
of sear 108 over projection 113a during insertion of legs 102 into
housing 110. Further advantageously, and as preferably embodied,
projection 113a may be formed simply by providing groove 114 in the
interior surface wall of housing 110. In this way, sear 108 can be
guided by groove 114 as legs 102 are inserted into housing 110.
Accordingly, after connector body 106 is assembled, it may be
releasably locked within connector housing 110 simply by inserting
legs 102 into housing 110 with sears 108 deflecting radially
inwardly as they ride over projection 113a and snapping back,
radially outwardly, in a ratchet-like fashion to lockably engage
lip 113 (See FIGS. 7 and 8) once surface 108a has passed lip 113.
In addition, since the free ends of legs 102 are "squeezed"
together in the radially inward direction as sear 108 rides over
projection 113a, there is no risk that such action will cause
disassembly of connector body 106 (i.e., disassembly of connector
front 100 from terminal housing 104) because projections 103 will
also be moved radially inwardly and, therefore, will not be moved
out of its abutting relation with surface 105b. Moreover, with the
outward portions of sears 108 exposed through apertures 112,
connector body 106 can be removed from housing 110 (e.g., for
checking conductor connections to the terminals), simply by pushing
the diametrically opposed sears 108 radially inwardly beyond lips
113 and withdrawing body 106.
Similarly, in order to disassemble connector body 106, legs 102 are
simply spread radially outwardly apart until projections 103 are
positioned radially outwardly beyond the radially outermost portion
of surface 105b and separating connector front 100 and terminal
housing 104. In this context, it is preferred that projections 103
do not extend the full thickness of legs 102 (see FIG. 1) so that
the legs are not over-stressed when spread apart during assembly or
disassembly.
Thus, it will be found that the double acting fastening means
according to the present invention not only provide dead front
surfaces on the connector front members, but they also obviate the
need for screws or other metallic fasteners for retaining any of
the component parts in assembled configuration. In addition, the
coupling between connector body 106 and connector housing 110 is
capable of withstanding substantial "pulling" forces before
separating because of the relatively large abutting surface areas
of surfaces 108a and 113 and the integral nature of legs 102 and
connector front 100.
As indicated above, the means for tighteningly grasping cable 130
to the connector assembly includes collar 116 which is threadably
engageable into the end of housing 110 opposite that to which
conductor body 106 is attached, with chuck means 120 positiond
therebetween, adapted to tighteningly grasp cable 130 as collar 116
is threaded onto housing 110. Advantageously, and as here
preferably embodied, means are provided for realeasably locking
collar 116 on housing 110, such as disclosed and claimed in U.S.
patent application Ser. No. 679,785, filed Apr. 23, 1976, now U.S.
Pat. No. 4,053,198, granted Oct. 11, 1977, assigned to the same
assignee as the present application which is hereby incorporated by
reference herein. Thus, collar 116 may be formed with slots 117 and
housing 110 may be provided with shaft/detent member 118 rotatably
mounted in a suitable recess formed in housing 110 with biasing
flange 118b abutting a suitable structure in housing 110. In
addition, since the connector means according to the present
invention may be adapted for relatively large cables, the detent
flange (indicated at 118a) may be relatively long to ensure firm
bearing within slots 117.
As preferably embodied, chuck means 120 are formed with extensions
122 extending oppositely from cable engaging portions 124.
According to the invention, extensions 122 are adapted to be
positioned behind sear means 108 when connector body 106 and
housing 110 are assembled and after the chuck means are tightened
on the cable, (explained more fully below) to prevent inadvertent
disassembly of body 106 and housing 110 when the cable is wired to
the connector assembly. Such inadvertent disassembly could
otherwise occur, for example, when the wired male and female
connectors are firmly grasped to be pulled apart for breaking the
electrical connection between two cables; sears 108 could
accidently be forced radially inwardly an amount sufficient to
become free of lips 113.
To this end, chuck means 120 are adapted to tighteningly grasp
cable 130 as collar 116 is threaded onto housing 110 and to
position extensions 122 behind sear means 108 when the collar/chuck
means have fully grasped cable 130. In addition, chuck means 120
are preferably adapted to retract extensions 122 from behind sear
means 108 when collar 116 is reverse threaded to loosen cable 130.
Accordingly, chuck means 120 is preferably integrally formed of a
generally flexible and resilient material such as type-6 Nylon and
includes four chuck elements (or cable-grasping portions) 124 which
are coupled to extensions 122 by relatively thin hinge portions
(indicated at 124a), with extensions 122 coupled together in a
generally symmetrical configuration by band 126. As preferably
embodied, the principal portions (elements 124 and extensions 122)
of chuck means 120 are adapted to slide in housing 110. To this
end, extensions 122 are positioned within circumferentially
undercut slots 123 (FIG. 3d) adapted to permit slidable movement of
extensions 122 therewithin in the longitudinal direction of the
assembled connector assembly but to prevent movement in the radial
and circumferential directions. As can be seen from FIG. 3 c, slots
123 preferably extend at least to about the edge of aperture 112
for providing support on the radially inward surface of extensions
122 to effectively reinforce them when they are located behind
sears 108 to prevent radially inward movement thereof, regardless
of the thickness of cable 130.
Advantageously, in order to retract extensions 122 from behind
sears 108 when disassembly is desired, chuck means 120 are formed
with biasing means in the form of resilient hook-like members 128
adapted to bear against edge 110a of housing 110. As preferably
embodied, the free end of each hook-like member 128 is located in a
recess 110b formed in edge 110a to ensure members 128 are held in
position to function as intended. Also advantageously, each slot
123 is formed with enlarged portion 123a to form corner-like
abutment surface 123b and each extension 122 is formed with
enlarged portion 122a proportioned to fit within enlarged slot 123a
and forming abutment surface 122b adapted to bear against surface
123b when the free ends of extensions 122 have moved a sufficient
amount behind sears 108 for preventing radially inward movement
thereof. Thus, the travel of extensions 122 needed to ensure firm
bearing behind sears 108 can be kept relatively small. Thus, it has
been found that a travel (t) adapted to provide engagement of about
0.090" of extensions 122 onto the radially inward surface of legs
102 is sufficient to prevent inadvertent depression of sears
108.
In operation, as collar 116 is tightened onto housing 110, chuck
elements 124 are first moved slightly longitudinally in the
direction of threading, until the back surfaces 122b of chuck means
120 abut surfaces 123b of housing 110, with extensions 122
simultaneously moved in the same direction whereby the free ends of
extensions 122 are moved behind sear means 108 until located in the
predetermined seating behind sears 108 when surface 122b abuts
surface 123b. Generally after extensions 122 have been fully seated
behind sears 108, further threading of collar 116 onto housing 110
urges the free ends of chuck elements 124 radially inwardly for
tighteningly grasping cable 130. Once the desired grasping is
achieved, collar 116 is releasably locked in that position by
flange 118a wedging into a slot 117.
When disassembly is desired, detent/shaft 118 is deflected radially
inwardly to remove flange 118a from within the slot 117.
Thereafter, collar 116 can be unthreaded from housing 110. As
collar 116 is unthreaded, chuck elements 124 are loosened from
cable 130 and hook-like biasing members 128 cause extensions 122 to
be withdrawn from behind sears 108, enabling connector body 106 and
housing 110 to be separated as described above.
Advantageously, sears 108 may be formed with radially inwardly
projecting protuberances 108b adapted to firmly bear against
extensions 122. Also advantageously, the free end edge of
extensions 122 are beveled to facilitate riding behind
protuberances 108b.
It will be readily appreciated from the foregoing that the
connector assembly according to the present invention enables the
use of universal parts in either the male or female connector
members. Thus, the terminal housings (104), the connector housings
(110), the collars (116) and the chuck means (120) may be
essentially identical for both male and female connector members,
as well as for various size cables. Virtually the only differences
reside in the connector fronts. The male connector front resembles
a generally flat disc with legs 102 extending therefrom and slots
to permit the prongs of the male plug contacts to extend
therethrough for insertion into the female member. The female
member is a generally cylindrical member with legs 102 extending
opposite its front face and having suitably formed recesses to hold
the receptacle contacts, as well as slots at its front face to
enable insertion of the plug prongs for engagement in the
receptacle contacts. Moreover, the front surface of the male
connector front is essentially flush with the front edge of housing
110, whereas the chamber in the female connector front, which
houses the receptacle terminals, extends beyond the front edge of
its connector housing, as shown in FIG. 8, such that legs 102 are
the same length for both male and female front members to enable
use of the same connector housing and terminal housing for both
male and female connector members.
Connection between the conductors in cable 130 and the various
contacts in the connector members (i.e., termination of the
conductors) is preferably carried out by wire clamp termination. To
this end, terminal housing 104 is formed with a plurality of
chambers 150 having a slightly enlarged slot portion adapted to
hold contact/terminal plate 152a into which is inserted screw 154
which, in turn, is threaded into contact/terminal plate 152b for
moving plate 152b relative to plage 152a, with opening 148 formed
in the side of housing 104 adapted to face cable 130 for
communicating such side with chambers 150 to permit insertion of a
conductor into recess 150. In addition, resilient material 156 is
positioned within each chamber 150 for urging plates 152a and 152b
towards each other for initially grasping the conductor when
inserted through opening 148 and into the space between plates 152a
and 152b and also for facilitating threading of screw 154 into
plate 152b in the event they become unthreaded.
It will be understood that once the conductor is positioned between
plates 152a and 152b, screw 154 is threaded into plate 152b (with
the head of screw 154 bearing against plate 152a) to firmly grasp
the conductor. It will also be understood that one of plates 152a
and 152b (preferably stationary plate 152a) is coupled to or forms
part of the electrical contact (i.e., the plug prong or the
receptacle contact).
Advantageously, opening 148 is tapered in the direction of
insertion of the conductor to facilitate insertion into chamber
150. As preferably embodied, such tapering is adapted to form a
generally rectangular window at the end of opening 148 which opens
into chamber 150. In this way, the wire elements of each conductor
will be apread (or flattened) slightly to facilitate insertion
between plates 152a and 152b.
Advantageously, the terminal portions of the male electrical
contacts may be formed at one end of a strip of metal whose other
end is proportional to form the blades (or prongs) of the male
connector, simply by dimensioning that end to fit within the slot
formed in chamber 150 and forming an aperture for permitting
insertion of screw 154. The terminal portions of the female
electrical contacts may be formed simply by folding a strip of
metal over itself, with its free ends proportioned in the desired
configuration for releasably grasping the male plug blades, and
forming an aperture in the folded end for permitting insertion of
screw 154, so the folded end can be inserted in the slot formed in
chamber 150. It will be understood that since the material making
up the male contacts is generally thicker than that of the female
contacts (as the male contacts must withstand axial forces caused
by insertion into the female receptacles) the female contacts can
be formed so that the thickness of the folded over end is equal to
about that of the male contact for fitting in the slots formed in
chamber 150, thereby enabling use of identical terminal housings
104 for both male and female connector sections.
Turning now to FIGS. 4a-b, there is shown another aspect of the
present invention which enables the use of wire clamp termination
for wiring the ground conductor of cable 130 to the ground terminal
in connector assemblies wherein the ground terminal is located in
the center of the conductor front member, such as in a
five-conductor cable connector. According to this aspect of the
invention, terminal housing 104 is formed with slot 132 extending
radially inwardly of housing 104 and including enlarged portion
132a located generally central of housing 104 (to hold the wire
clamping terminal portions 144 and 146 of the ground contact) and
enlarged portion 132b located at the radially outward end of slot
132 to communicate slot 132 with the ambient surroundings. Thus, as
shown in FIG. 4b, enlarged portion 132a defines radially inwardly
facing surface 135 and enlarged portion 132b defines radially
outwardly facing surface 133. In addition, ground termination screw
138 is formed not only with head 140, but also circular flange
portion 139 generally near its threaded portion.
Therefore, according to this aspect of the invention, ground
termination screw 138 may be retained generally in position by
inserting it into slot 132 with the inside surface of head 140
abutting surface 135 and the radially outwardly facing surface of
flange 139 abutting surface 133.
As preferably embodied, terminal housing 104 is also formed with
flange 136 and flange 134 to form continuations of surfaces 135 and
133, respectively, to provide additional surface areas against
which the radially inward surface of head 140 and the radially
outward surface of flange 139, respectively, can bear. In addition,
connector front 100 is advantageously formed with flange 142
adapted to project toward screw 138 from the opposite side thereof
as flange 136 to ensure screw 138 remains in position. In this way,
connection of the ground conductor in cable 130 to the ground
contact in the connector member (in both plug and receptacle
members) can be carried out by essentially the same wire clamp
termination method as the other conductor terminations rather than
wrapping the ground conductor around the ground screw (i.e. by
binding screw termination), where the ground contacts are located
generally centrally of the connector front members 100.
To this end, enlarged portion 132a is a box-like chamber which is
open on the side of housing 104 adapted to face connector front 100
for receiving the termination portion of the ground contact. In
addition, screw 138 is inserted into an aperture (not shown) formed
in plate/contact element 144, dimensioned between the diameter of
screw 138 and that of flange 139 for enabling slidable insertion of
screw 138 thereinto but preventing insertion beyond flange 139, and
screw 138 is threaded into plate/contact element 146, formed with
an aperture suitably dimensioned to accommodate such threading. One
of plates 144 and 146, preferably plate 146 since it can remain
essentially stationary relative to screw 138, forms the terminal
portion of ground contact 145 (whether a plug prong or a receptacle
contact).
Thus, similar to the termination of the other contacts described
above, screw 138 is unthreaded to separate plate members 144 and
146. The ground conductor is thence inserted through aperture 148
which communicates chamber 132a with the other side of housing 104
(i.e., the side opposite that adapted to abut connector front 100)
and into the space between plates 144 and 146. Thereafter, screw
138 is threaded into plate 146 to bring plates 144 and 146 together
for retaining the ground conductor therebetween and making secure
electrical connection between the ground conductor and ground
terminal 145.
It will be understood by those skilled in the art that connector
front 100, terminal housing 104, connector housing 110, collar 116
and chuck 120 can all be molded from an injection moldable plastic
material. Moreover, the component parts are universal in that they
can be proportioned so that one size can be adapted to be wired to
virtually any sized cable. In addition, and specifically with
respect to terminal housing 104, the mold can be provided with
inserts for preventing formation of one or more terminal containing
recess, such as, for example, for a four-conductor connector, an
insert can be applied to the mold to prevent formation of slot 132
so that only four functional terminal recesses (indicated at 150 in
FIG. 4b, with exemplary wire clamp terminal plates and screws
indicated in phantom at 152a/152b and 154, respectively, are
contained in terminal housing 104.
It will readily be appreciated by those skilled in the art that the
invention in its broader aspects are not limited to the specific
embodiments herein shown and described. Rather, variations may be
made therefrom within the scope of the accompanying claims, without
departing from the principles of the invention and without
sacrificing its chief advantage.
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